Thread: How would this be done?

If you're making less than say 10, bite the bulet and just buy them

To make one, I'd use MDF (or high density board) of the appropriate thickness, a router, lots and lots of templates -- each shaped by hand -- and at a guess 3 or 4 diferent router bits you may have to get one custom ground for the bevel angle

Fo just on, I'd look to mostly working by hand

Yup.

I'd use templates to trim around each raised section, then use a router sled to clean out the excess between them, bringing the rest of the panel down to the same height..

Suitable thickness MDF for the base, then stick the sticky-up bits on with epoxy (fillet the area where they meet) and spray paint the whole thing to one colour.

You'll never know that there were two bits.

If only doing a few, I'd do the cowling/visor bits as three parts so I could just cut the slope out with a jigsaw then glue all the bits up.

Next try after that would be either cutting a full-cowl-sized piece of MDF with a bandsaw or wasting off the excess with a router, with the part held in a jig to get the slope.

Alternatively, make a mould and cast one in fiberglass!

Thanks for the replies... some good ideas there, exactly what I was looking for